Needle blank feeding apparatus

ABSTRACT

A needle machining apparatus which presents a stock needle to a device for boring a hole in the needle. The apparatus also includes a needle feeding apparatus which provides high speed feeding of blank needles for the needle machining apparatus. A method for high speed feeding of needles for subsequent laser drilling is also disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a needle machining apparatus whichpresents a stock needle to a device for boring a hole in the needle forsubsequently securing a suture thereto. More particularly, the presentinvention relates to a high speed needle feeding apparatus forcontinuously feeding needle blanks for subsequent laser drilling.

2. Description of the Related Art

Surgical sutures are generally manufactured by first longitudinallydrilling a hole through the end face of a blank stock needle, bendingthe needle to a desired curvature, inserting an appropriate suture intothe hole and crimping or otherwise securing the suture material to theneedle. Generally, there are numerous ways to drill or cut the hole inthe end face. For example, the hole may be made by drill machining,electric discharge machining, laser beam machining, electron beammachining and the like. With the advent of microsurgical procedures,surgical sutures have become increasingly smaller in size, thus makingit more complex and costly to manufacture the surgical needles. Inparticular, one aspect of surgical suture manufacturing which has becomecomplex is drilling the hole in the needle.

A common procedure for making a hole in a surgical needle utilizes laseror electron beam machining. In order to utilize these methods in aproduction environment, techniques have been developed to continuouslypresent a blank needle before the beam for cutting. One such techniqueincludes presenting the blank needle from a rotary spool which issequentially rotated to present an end face in line with the focal planeof the laser or electron beam. However, one drawback to this techniqueis that the rotating spool must stop before the beam is impinged on theneedle. In order to operate properly the spool must come to a rest atprecisely the same position aligned with the focus point of the beam. Ifthe needle in the rotating spool is not aligned with the focus point ofthe beam, even by an infinitesimal amount, the centrality of the holewould be off center, thereby reducing the accuracy of the productionprocess and ultimately resulting in increased defective quantities ofneedles. Currently, rotary spool systems are unable to obtain theprecise positioning required for laser or electron beam machining. Thislack of precision is magnified as the speed in which the blank needle ispresented increases. As a result, the reliability and accuracy of rotaryspool feeding systems is unacceptable in a high volume productionenvironment.

Another technique utilized has been to bundle blank needles into acontainer, digitize an image of the needle faces in the bundle and movethe laser or electron beam to focus sequentially on each needle beforefiring the beam. These types of beam machining devices also havedrawbacks, such as the need to optically determine where each needle isand then move the beam to coincide with the longitudinal axis at thecenter of the needle. Such systems are complex and require additionalsteps in order to determine the precise position of each needle. As aresult, the speed of producing sufficient quantities to satisfyproduction needs is decreased.

Therefore, a need exists for a precise needle blank feeding system whichcan be reliably operated at high speeds and which does not requiremovement of the laser or electron beam.

SUMMARY OF THE INVENTION

The present invention relates to an apparatus for presenting needleshanks to a device for boring a hole in the needle shank. The apparatusincludes a frame, guide means secured to the frame for transferring theneedle shank between a needle receiving position and a hole creatingposition, blocking means slidably secured to the frame for positioningthe needle shank a predetermined distance from the hole boring device,pusher means slidably secured to the frame for sliding the needle shankto abut the blocking means, such that the needle shank is positionedfrom said hole boring device said predetermined distance, and jaw meansslidably secured to said frame for maintaining the needle shank in saidhole creating position. The invention also provides for a laser boringsystem having a laser operated in conjunction with the needle presentingapparatus. A method is disclosed for presenting the needle shanks forlaser boring which utilizes the apparatus of the present invention.

The apparatus of the present invention permits needle blanks to beprecisely and accurately positioned for end drilling. Advantageously,the apparatus sequentially advances and accurately positions needleblanks for end drilling at a very high repetition rate, which allows ahigh volume of needle blanks to be processed in a relatively shortperiod. Indeed, with the apparatus of the present invention needleblanks are sequentially positioned for end drilling at a repetition rateapproaching the cycle time of the laser. In addition to productionvolume considerations, the high repetition rate is also importantbecause a laser is most efficient and reliable when operated at aconsistent pulse cycle. Thus, a laser produces the most consistentneedle holes when operated substantially continuously at a normal cycleof between about 1Hz. and 10 Hz., preferably about 4 Hz. Prior to thepresent invention it has not been possible to accurately feed andposition needle blanks at such rapid speeds.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention will become more readily apparentand may be understood by referring to the following detailed descriptionof an illustrative embodiment of the invention, taken in conjunctionwith the accompanying drings, in which:

FIG. 1 is a perspective view from the rear of the needle machiningsystem of the present invention;

FIG. 2 is a rear view of a needle feeding apparatus which forms part ofthe system of FIG. 1, illustrating te primary drive system and theadjustable base assembly;

FIG. 3 is a perspective view of a needle shank machined by the needlemachining system of FIG. 1;

FIG. 4 is a top view, partially in cross-section, of the needl fedingapparatus taken along lines 4--4 of FIG. 2;

FIG. 5 is a left side view of a portion of the adjustable ase assemblytaken along lines 5--5 of FIG. 2;

FIG. 6 is a left side view, partially in cross-section, of the primarydrive system taken along lines 6--6 of FIG. 2;

FIG. 7 is a front view of a portion of the needle positioning systemethe needle machining system of FIG. 1 taken along lines 7--7 of FIG. 6;

FIG. 8 is a top view, partially in cross-section, of the needlepositioning system taken along lines 8--8 of FIG. 7;

FIG. 9 is a front view, partially in cross-section, of the needlepositioning system taken along lines 9--9 of FIG. 8;

FIG. 10 is a perspective view with parts separated, of the needlepositioning system of FIG. 7, showing the jaw assembly, pusher assembly,guide assembly, and the blocking system;

FIG. 11 is a front view of the needle positioning system tak ong lines11--11 of FIG. 8;

FIG. 12 is a top plan view of the needle blank supply hopper assembly ofFIG. 7, illustrating a portion of an anti-binding system;

FIG. 12a is a cross-sectional view of the cycle wheel which forms partof the anti-binding system taken along lines 12A--12A of FIG. 12.

FIG. 13 is a top view, partially in cross-section, of a portion of theneedle detection system taken along lines 13--13 of FIG. 7;

FIG. 14a is a front view, partially in cross section, of the needlepositioning system of FIG. 7 and a portion of the supply hopper assemblyof FIG. 12, illustrating a row of needle blanks in position prior tocreation of the hole, and a needle blank being released after creationof the hole;

FIG. 14b is a front view similar to FIG. 14a, illustrating the nextneedle blank in position in the needle carriage prior to transfer to thehole creation position;

FIG. 14c is a front view similar to 14b, after the needle carriage hastransferred the needle to one jaw in the hole creation position, priorto creation of the hole; and

FIG. 14d is a view similar to FIG. 14c, illustrating the needle blank inthe hole creating position gripped by both needle gripping jaws aftercreation of the hole.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now in detail to the drawings, in which like referencenumerals identify similar or identical elements throughout the severalviews, FIG. 1 illustrates the needle machining system 10 of the presentinvention which includes a hole making device 12, a needle feedingapparatus 14, a control system 16 and an imaging system 18. The holemaking device 12 preferably comprises a laser, however, it should beunderstood that the hole making device may include a wide variety ofmachinery, such as, drill machinery, electric discharge machiningdevices and electron beam machining devices.

Referring to FIGS. 1 through 6, the needle feeding apparatus 14 ofsystem 10 includes frame 20, drive system 22, and needle positioningsystem 24. In the preferred embodiment, shown in FIGS. 2 and 6, frame 20has adjustable base assembly 26, vertical support 28 secured to base 36by side walls 50 and 52, and operational platform 30 secured to verticalsupport 28. Adjustable base assembly 26 is provided to support theoperational components of needle feeding apparatus 14 and to provideproper alignment and adjustment of the position of the needle prior todrilling or machining the hole. Frame 20 is movable by adjusting theposition of adjustable base assembly 26 to ensure that the hole iscentered in the face 35 of the needle 37 and extends linearly therein apredetermined depth, as shown in FIG. 3. The depth of the hole may varydepending on the type of suture to be inserted therein and the diameter,length and composition of the needle.

Referring to FIGS. 2 and 4, adjustable base assembly 26 includes basesupport members 32, base retainer 34 and base 36 which provide foradjustment of the needle in five axes. Base retainer 34 is secured tobase supports 32, with vertical adjusting members 38, while base 36 isslidably secured to base retainer 34 with set screws 40. An example ofthe five axes adjustment of adjustable base assembly 26 lies within thethree dimensional rectangular coordinate system. The base is adjustablein the positive and negative x direction, the positive and negative ydirection, the positive and negative z direction or any combinationthereof. In addition, rotational adjustment is provided in the x-y planeand in the y-z plane. To illustrate and referring to FIG. 4, x-planeadjusting members 42 provide left to right adjustment of base 36, whiley-plane adjusting members 44 provide back and forth adjustment of base36. As shown in FIG. 5, vertical adjustment of base 36 is provided byvertical adjusting members 38. Rotational movement of base 36 isprovided by properly adjusting y-plane adjusting members 44 for x-yplane rotation and/or vertical adjusting members 38 for y-z planerotation. Preferably, the various adjusting members are screws whichcause the corresponding motion as described. However, bolts,micrometers, and the like may be utilized as aligning members. It shouldbe noted that the underlying principle in adjusting base 36 is toproperly position the longitudinal axis of the needle within the focalplane or cutting axis of the laser, so that the hole is substantiallycentered within needle 37, as shown in FIG. 3. Gauges 48 may be providedto ensure that base 36 is symmetrically adjusted in each axis the samedistance.

To supplement the positioning of the needle in the hole creatingposition an imaging system 18 is provided to assist in the initialadjustment of the needle. As shown in 5 FIG. 1, imaging system 18generally includes video camera 54, lens assembly 56 and video monitor58. In the preferred embodiment, lens assembly 56 is connected to focallens 60 of laser 12 so that the focal plane of lens assembly 56coincides with the focal plane of laser 12. Video camera 54 is connectedto lens assembly 56 and electrically connected to video monitor 58.Cross-hairs 59 superimposed on the video image correspond to the focuspoint of laser 12. As a result, the displayed image on video monitor 58includes needle face 35 and cross-hairs 59, as shown in FIG. 1. In thisconfiguration, imaging system 18 allows an operator to observe theneedle face 35 in the hole creating position and adjust the frame, asdiscussed above, to align the longitudinal axis of the needle with thecenter point of the intersecting cross-hairs.

Drive system 22 will now be described with reference to FIGS. 2, 6, 8and 9. Preferably, drive system 22 includes; a) motor 62 secured tovertical support 28; b) primary drive shaft 64 rotatably secured tosupport 28 having primary drive wheel 66 secured thereto; c) clutchassembly 68 operatively connected to primary drive shaft 64; d) primarycam system 70 connected to primary drive shaft 64; e) secondary driveshaft 72 operatively connected to primary drive shaft 64; and f)secondary cam system 74 connected to secondary drive shaft 72.

Referring to FIG. 2, motor 62 rotates primary drive wheel 66 via primarydrive belt 76 connected between primary drive wheel 66 and motor drivewheel 67. Although primary drive belt 76 is utilized to transfer therotational movement of motor 62 to primary drive shaft 64 any otherknown device may be used to transfer the rotational movement, such asgears, chain links and the like. The rate at which the motor rotatesvaries with the operational speed of needle machining system 10, whichis regulated by control system 16. For example, if a laser is utilizedto make the hole, the motor should rotate at a speed which allowsmaximum use of the laser while maintaining the accuracy of needlefeeding apparatus 14. Thus, if the laser is programmed to fire at a rateof 4 Hertz (Hz), the motor must rotate so that 4 needles per second arepositioned in tke hole creating position. Similarly, if the laser isprogrammed to operate at 2 Hz. the motor must rotate so that 2 needlesper second are positioned in the hole creating position.

Referring to FIG. 6, clutch assembly 68 is provided to transferrotational movement of primary drive wheel 66 to primary drive shaft 64.The clutch assembly is shown in phantom in FIG. 2 for the purpose ofclearly illustrating the primary drive shaft and its associatedcomponents, however, the clutch assembly is shown in detail in FIG. 6.Preferably, clutch assembly 68 includes solenoid 78, solenoid arm 80 andbrake arm 82. However, other types of known clutch mechanisms arecontemplated. To activate clutch assembly 68 solenoid 78 is energized,preferably from a 24 volt electrical signal from control system 16,which indicates that the laser is ready to activate. Energized solenoid78 causes solenoid arm 80 to retract so as to disengage from brake arm82. Release of brake arm 82 allows primary drive shaft 64 to rotateuntil solenoid 78 is deactivated. Deactivation of solenoid 78 causessolenoid arm 80 to protract and engage brake arm 82 so as to inhibitprimary drive shaft 64 from rotating.

Referring to FIGS. 6 and 8, primary cam system 70 is secured to primarydrive shaft 64 to translate the rotational movement of primary driveshaft 64 to the reciprocating movement of pusher system 84 and guideassembly 86. Primary cam system 70 includes upper primary cam 88,intermediate primary cam 90 and lower primary cam 92, where upperprimary cam 88 and intermediate primary cam 90 reciprocate guideassembly 86 and lower primary cam 92 reciprocates pusher system 84.

Secondary drive shaft 72 is rotatably secured to vertical support 28 andhas secondary drive wheel 94 secured thereto. Secondary drive wheel 94is operatively connected to intermediate drive wheel 96 on primary driveshaft 64, so as to transfer rotational movement of primary drive shaft64 to secondary drive shaft 72. Typically, drive belt 98 which passesthrough vertical support 28, is employed to connect primary drive shaft64 to secondary drive shaft 72. However, other known techniques may beutilized to transfer the rotational movement between the shafts, such asgears, chain links and the like.

Referring to FIGS. 8 and 9, secondary cam system 74 is secured tosecondary drive shaft 72 to translate the rotational movement ofsecondary drive shaft 74 to the reciprocating movement of blockingsystem 100 and jaw assembly 102. Secondary cam system 74 includes uppersecondary cam 104 and lower secondary cam 106, where upper secondary cam104 reciprocates jaw assembly 102 and lower secondary cam 106reciprocates blocking system 100.

The needle positioning system 24 will now be described with reference toFIGS. 6 through 11. In the preferred embodiment, shown in FIG. 10,needle positioning system 24 includes guide assembly 86, blocking system100, pusher system 84 and jaw assembly 102, which are slidably securedto operational platform 30.

Referring to FIG. 8, guide assembly 86 includes carriage 108 and guidemember 110. Carriage 108 is slidably secured to guide track 112 andreciprocates between a needle receiving position and a hole creatingposition. Guide member 110 is slidably secured within guide track 112 ata point adjacent the hole creating position and in opposition tocarriage 108. In the preferred embodiment, carriage 108 and guide member110 are fabricated from an aluminum-bronze alloy. If necessary ordesirable a lubricant may be added to carriage 108, guide member 110and/or guide track 112 to provide lubrication for guide assembly 86.However, it is also contemplated that guide assembly 86 may befabricated from materials, such as an oil or other lubricant impregnatedmaterial, which may be used in conjunction with a lubricating substanceto assist the sliding motion.

As noted above and referring to FIGS. 6 and 8, reciprocating movement ofcarriage 108 is caused by primary cam system 70. Cooperation betweenupper primary cam 88 and carriage spring 114 causes carriage arm 116 toreciprocate. Reciprocating movement of carriage arm 116 causes carriage108 to reciprocate between the needle receiving position and the holecreating position. Reciprocating movement of guide member 110 is alsocaused by primary cam system 70, however, guide member 110 isreciprocated between the hole creating position in opposition tocarriage 108 and an open position in which guide member 110 is displacedfrom the hole creating position. To illustrate, cooperation betweenintermediate primary cam 90 and guide spring 118 causes guide arm 120 toreciprocate. Reciprocating movement of guide arm 120 causes guide member110 to reciprocate between the hole creating position and the openposition.

The needle receiving position represented by the letter "A" in FIG. 9,is the plane along guide track 112 where a needle is supplied tocarriage 108. The hole creating position on the other hand, is the planealong guide track 112 where the needle is positioned for subsequentdrilling, as shown by the letter "B" in FIG. 9. Generally, the suppliedneedle is oriented so that the longitudinal axis of the needle issubstantially perpendicular to the longitudinal axis of guide track 112with one face of the needle positioned toward the laser. It should benoted, however, that the requirement for orientation of the longitudinalaxis of the needle is such that the needle face coincides with the focuspoint or cutting point of the laser so that the hole created is centeredon the front face of the needle and extends linearly into the needle, asshown in FIG. 3.

Referring again to FIGS. 6 and 8, pushing system 84 is provided to pushthe needle along its longitudinal axis in the hole creating position toa predetermined distance from laser 12. Pushing the needle toward laser12 enables jaw assembly 102 to grasp the needle, while the predetermineddistance between the needle and laser 12 ensures the precision of thedepth and shape of the hole and, in some instances, prevents overheatingand discoloration of the needle when drilling. As noted above, thepushing system 84 is activated by lower primary cam 92 of primary camsystem 70. To illustrate, cooperation between lower primary cam 92 andwheel 93 against the biasing force of pusher spring 122 causes pusherpin 124 to vertically reciprocate. Reciprocating movement of pusher pin124 causes pusher bar 126 to reciprocate between the hole creatingposition and an open position displaced from the hole creating position.

Referring to FIGS. 8 and 11, blocking system 100 is provided to preventthe needle from extending a predetermined distance beyond jaw assembly102 and guide assembly 86 in the direction of the laser. As a result,pusher system 84 may push the needle toward the laser a maximum distancewhich abuts blocking system 100. In the preferred embodiment, theblocking system includes a shutter 128 positioned adjacent to jawassembly 102 and slidably secured to operational platform 30.Cooperation between lower secondary cam 106 of secondary cam system 74and shutter spring 130 causes shutter arm 132 to reciprocate.Reciprocating movement of shutter arm 132 causes shutter 128 toreciprocate along a path parallel to guide 112, between an intersectingposition, where shutter 128 intersects the focal or cutting plane of thelaser, and a retracted position where shutter 128 no longer intersectsthe laser's focal or cutting plane.

Referring to FIGS. 8, 10 and 11, jaw assembly 102 includes a pair ofjaws 134 and 136 which are preferably fabricated from carbide, to enablejaw assembly 102 to withstand arcing caused when the laser beam isimpinged on the needle shank without deteriorating. Fixed jaw 134 isrigidly secured to operational platform 30 adjacent guide 112 so as tohave fixed gripper 138 in communication with the plane of the holecreating position. Movable jaw 136 is slidably secured to operationalplatform 30 adjacent guide 112 so as to have movable gripper 140 slideinto communication with the plane of the hole creating position inopposition to fixed gripper 138. As noted above, jaw assembly 102 isactivated by upper secondary cam 104 of secondary cam system 74 andmaintains the needle in the hole creating position until the hole hasbeen created. To illustrate, cooperation between upper secondary cam 104and jaw spring 142 causes jaw arm 144 to reciprocate. Reciprocatingmovement of jaw arm 144 causes movable jaw 136 to move between an openposition which allows an existing needle between the jaws to fallthrough, and a closed position which grasps the new needle to bedrilled.

Turning to FIGS. 6, 7 and 9, supply hopper 146 is provided tocontinuously supply blank needles to guide assembly 86. In the preferredembodiment, supply hopper 146 is secured to operational platform 30adjacent the needle receiving position of guide assembly 86 andcontinuously supplies needles thereto. However, supply hopper 146 may bereleasably secured to platform 30 such that supply hopper 146 can bereplaced with a new full hopper assembly after the existing supply ofneedles has depleted. For example, supply hopper 146 may be secured toplatform 30 by a track which receives flanges (not shown) positioned onsupply hopper 146, to frictionally secure supply hopper 146 to platform30. Another example for releasably securing supply hopper 146 toplatform 30 may be to provide a snap-lock mechanism in which a firstflange on supply hopper 146 snaps into a corresponding channel inplatform 30, while a second flange on supply hopper 146 snaps into acorresponding channel in a spring loaded member secured to platform 30.The spring loaded member would allow an operator to release the supplyhopper from the platform by simply retracting the spring loaded memberso that the second flange is exposed, thus enabling the operator to tiltor pivot the supply hopper and disengage the first flange.

Referring to FIGS. 6, 7 and 12, supply hopper 146 is also provided withan anti-binding system which prevents needles within supply hopper 146from binding at the point where the needles are supplied to guideassembly 86. Preferably, anti-binding system 148 includes cycle wheel150, gear 152, drive means such as chain 154 and hopper motor 156. Cyclewheel 150 is rotatably secured within supply hopper 146 at a pointadjacent to needle supply opening 158, thereby ensuring continuous andsequential gravity feeding of needles through needle supply opening 158,as shown in FIGS. 12, 12a and 14a. Gear 152 is secured to cycle wheel150 on the exterior of supply hopper 146 and is operatively connected tohopper motor 156 by drive chain 154. Hopper motor 156 continuouslyrotates cycle wheel 150 in a direction opposite the direction needlesare supplied to guide assembly 86, i.e., a counter-clockwise direction,which prevents needles from building-up and binding at needle supplyopening 158. Preferably, cycle wheel 150 is a twenty-four sided, aboutone-half inch diameter wheel which is fabricated from a polyurethanematerial to prevent the needles from binding at needle supply opening158, as shown in FIG. 14a. Utilization of a polyurethane material alsoprevents excessive marring of the needle shank surface. However, cyclewheel 150 may be fabricated from other suitable materials such asrubber.

To illustrate the dimensioning of cycle wheel 150, FIG. 12a shows cyclewheel 150 divided into four quadrants having six sides within eachquadrant. As shown, the first quadrant begins with side below side 150dand ends with side 150a the sixth side. The second quadrant begins withthe side to the left of side 150a and ends with side 150b, the twelfthside. The third quadrant begins with the side above side 150b and endswith side 150c, the eighteenth side. The fourth side begins with theside to the right of said 150c and ends with side 150d, the twentyfourth side. However, cycle wheel 150 may be in other knownconfigurations which prevent binding of the needle at the needle supplyopening.

Referring again to FIG. 6, receiving hopper 160 may also be provided toreceive the needles after the hole has been created therein. Receivinghopper 160 is releasably secured to frame 20 at a point aligned incommunication with the hole creating position. Preferably, receivinghopper 160 is releasably secured to frame by positioning receivinghopper 160 on platform 161 secured to frame 20, so as to releasablymaintain receiving hopper 160 in communication with the hole creatingposition. After a hole has been created in a needle, movable jaw 136 ismoved to release the needle, which drops by gravity into receivinghopper 160.

Referring again to FIG. 1, control system 16 is connected to laser 12and needle feeding apparatus 14 and provides control signals thereto.Preferably, control system 16 is programmable which enables the operatorto set the desired operational speed of needle feeding apparatus 14 andlaser 12. An example of a suitable control system includes a GE-Fanuc9030 Programmable Controller, a LCD display manufactured by HornerElectric and numerous control switches and indicators. In order toproperly operate, the timing for activating laser 12 and needle feedingapparatus 14 should be synchronized so that the laser cannot activateuntil the needle is present in the hole creating position. To accomplishthis, it is preferred that the operating frequency of the laser beprovided by the control system. For example, if the desired operatingspeed of the system is 240 needles per minute (4 Hz) control system 16will supply a 4 Hz signal to the laser. Control system also activatessolenoid 78, shown in FIG. 6, so that the operation of needle feedingapparatus 14 is synchronized with the firing of the laser. As notedabove, control system 16 also provides the variable voltage to motor 62,shown in FIG. 2.

Referring to FIGS. 2, 7 and 13, it is also preferred that needledetecting system 162 be provided to ensure that a needle is present inthe hole creating position prior to activating the laser. When no needleis present, needle detecting system 162 inhibits the laser fromactivating so that the laser beam does not accidentally impinge themechanical structure of needle feeding apparatus 14. Preferably, needledetecting system 162 includes photo proximity switch 164 and photosensor 166 connected to proximity switch 164. When activated, proximityswitch 164 sends a signal to control system 16 so as to inhibit thelaser from activating if a needle is not present. Photo sensor 166 issecured to vertical support 28 by bracket 167 so that photo sensor 166is positioned within close proximity to the hole creating position todetect a needle positioned in the hole creating position.

An operation cycle of needle feeding apparatus 14 will be discussed withreference to FIGS. 6 and 8. Initially, solenoid 78 retracts solenoid arm80 which allows clutch assembly 68 to activate. Activation of clutchassembly 68 causes primary drive shaft 64 to rotate. Rotational movementof primary drive shaft 64 causes primary drive wheel 66 and primary camsystem 70 to rotate. Rotational movement of intermediate drive wheel 96rotates secondary drive shaft 72 and ultimately secondary cam system 74.The timing pattern of the actuation of the cam systems is as follows:upper secondary cam 104 of secondary cam system 74 initially causes jawassembly 102 to open while upper primary cam 88 and intermediate primarycam 90 of primary cam system 70 causes guide assembly 86 to open. Atthis point any needle which may be in the hole creating position will bereleased and subsequently fall, shown in FIG. 14a, into the receivinghopper.

Once jaw assembly 102 and guide assembly 86 have opened, lower primarycam 92 of primary cam system 70 causes pushing system 84 to retract fromthe hole creating position. Blocking system 100 then slides alongplatform 30 adjacent jaw assembly 102 to intersect the hole creatingposition in response to lower secondary cam 106. In the intersectingposition, blocking system 100 prevents the needle from extending beyondguide assembly 86 and jaw assembly 102 a predetermined distance, asnoted above. At this point, guide assembly 86, in response to upper andintermediate cams 88 and 90 respectively, moves to the needle receivingposition, to receive a new needle from supply hopper 146, as shown inFIG. 14b. Guide assembly 86 continues to move with the needle engagedtherein until the needle is positioned at least partially in the holecreating position, as shown in FIG. 14c. Pushing system 84 then advancestowards jaw assembly 102 to push the needle to the desired distance fromthe laser drill, as noted above. In the preferred embodiment, pushingsystem 84 advances the needle to abut blocking system 100 so that theend face of the needle is positioned a predetermined distance from thelaser, as noted above.

Once the needle is completely positioned in the hole creating position,jaw assembly 102 closes, in response to upper secondary cam 104, so asto firmly maintain the needle in the hole creating position, as shown inFIG. 14d. Blocking system 100 retracts to allow the focus point of laser12 to coincide with the center of the needle face 35.

Once blocking system 100 retracts the cycle of loading the needle hasended and clutch assembly 68 disengages causing the cam assemblies tocease rotating. A cycle end switch activates and sends a signal tocontrol system 16 indicating the cycle has ended and a needle is inposition. Preferably, as shown in FIG. 2, cycle end switch 168 is aproximity switch which is activated when cycle pin 170 rotates pastproximity switch 168. Upon receiving the cycle end signal, controlsystem 16 then activates unless, as noted above, needle detecting system162 fails to detect the presence of a needle. Activation of laser 12causes a laser beam to strike the needle, thereby creating a hole in theneedle, having a predetermined length along the longitudinal axisthereof, as noted above.

It will be understood that various modifications can be made to theembodiments of the present invention herein disclosed without departingfrom the spirit and scope thereof. Therefore, the above descriptionshould not be construed as limiting the invention but merely asexemplifications of preferred embodiments thereof. Those skilled in theart will envision other modifications within the scope and spirit of thepresent invention as defined by the claims appended hereto.

What is claimed is:
 1. An apparatus for presenting needle shanks to adevice for creating a hole in a needle shank, which comprises:a frame;guide means secured to said frame for transferring a needle shankbetween a needle receiving position and a hole creating position;blocking means slidably secured to said frame for positioning the needleshank a predetermined distance from said hole creating device; pushermeans slidably secured to said frame for sliding the needle shank toabut said blocking means, such that the needle shank is positioned fromsaid hole creating device said predetermined distance; and jaw meansslidably secured to said frame for maintaining the needle shank in saidhole creating position.
 2. The apparatus according to claim 1, furthercomprising means for driving said guide means, said blocking means, saidpusher means and said jaw means in a predetermined sequence.
 3. Theapparatus according to claim 2, wherein said hole boring device is alaser.
 4. The apparatus according to claim 2, wherein said blockingmeans is movable in response to said drive means between a retractedposition and a position intersecting said hole creating position.
 5. Theapparatus according to claim 4, further comprising:means for verifyingthe presence of the needle shank in said hole creating position; andmeans for inhibiting said hole boring device from activating in responseto an indication from said verifying means of the absence of a needleshank.
 6. The apparatus according to claim 2, further comprising controlmeans for controlling and coordinating activation of said drive meansand said hole boring device.
 7. The apparatus according to claim 6,wherein said control means is programmable to set the desired operatingspeed of said needle presenting apparatus and said hole boring device.8. The apparatus according to claim 1, further comprising means attachedto said frame for supplying the needle shanks to said guide means. 9.The apparatus according to claim 8, further comprising means associatedwith said needle supplying means for preventing the needles from bindingwithin said needle supplying means.
 10. The apparatus according to claim9, wherein said binding preventing means comprises a rotatable toothedwheel positioned within said needle supplying means.
 11. The apparatusaccording to claim 8, further comprising means attached to said framefor receiving the needle shanks after boring of a hole in said needleshanks.
 12. The apparatus according to claim 5, further comprisingimaging means for verifying alignment of the needle with a focal planeof said hole boring device, said imaging means having a focal planealigned with the focal plane of said hole boring device.
 13. Theapparatus according to claim 2, wherein said drive means comprises:amotor; first drive shaft means having first gear means operativelyconnected to said motor for rotating said first drive shaft means;second gear means connected to said first drive shaft means andoperatively connected to third gear means connected to second driveshaft means for transmitting rotational movement from said first driveshaft means to said second drive shaft means; first cam means connectedto said first drive shaft means for reciprocating said pusher means andsaid guide means; second cam means secured to said second drive shaftmeans for reciprocating said jaw means and said blocking means; andclutch means operatively connected to said first drive shaft means forpreventing said first and second cam means from rotating when saidneedle is in said hole creating position.
 14. The apparatus according toclaim 13, further comprising means for disengaging said clutch meanswhen the needle shank is positioned in said hole creating position. 15.The apparatus according to claim 1, wherein the frame includes means foradjusting the position of the axis of the needle shank within said holecreating position such that the hole created by the hole boring deviceextends linearly along the longitudinal axis of the needle shank. 16.The apparatus according to claim 15, wherein the adjustment meansprovides five axes adjustment of the needle.
 17. The apparatus accordingto claim 1, wherein said jaw means comprises:a fixed jaw member securedto said frame and positioned in aligned communication with said holecreating position; and a movable jaw member slidably secured to saidframe such that said movable jaw reciprocates into aligned communicationwith said hole creating position opposite said fixed jaw member.
 18. Theapparatus according to claim 17, wherein said fixed and movable jawmembers are fabricated from carbide.
 19. The apparatus according toclaim 2, wherein said guide means comprises:a first member slidablypositioned on said frame to facilitate positioning of the needle in saidhole creating position, said first member being operatively connected tosaid drive means such that said first member reciprocates between afirst position in aligned communication with said hole creating positionand a second open position; and a second member slidably positioned onsaid frame to facilitate positioning of the needle in said hole creatingposition, said second member being operatively connected to said drivemeans such that said second member is movable between said needlereceiving position and said hole creating position.
 20. An apparatus forpositioning surgical needle shanks for laser drilling, which comprises:aframe; guide means secured to said frame and operatively connected to afirst drive means for transferring a needle shank between a needlereceiving position and a hole creating position; blocking means slidablysecured to said frame and operatively connected to a second drive meansfor positioning the needle shank a predetermined distance from a laser;pusher means slidably secured to said frame and operatively connected tosaid first drive means for sliding the needle shank towards saidblocking means in response to a first drive means, such that the needleshank is positioned from said laser said predetermined distance; and jawmeans slidably secured to said frame and operatively connected to saidsecond drive means for maintaining the needle shank in said holecreating position in response to said second drive means.
 21. Theapparatus according to claim 20, further comprising:means for verifyingthe presence of the needle shank in said hole creating position; andmeans for inhibiting said laser from activating in response to anindication from said verifying means of the absence of a needle shank.22. The apparatus according to claim 21, further comprising controlmeans for controlling and coordinating activation of said first andsecond drive means and said laser.
 23. The apparatus according to claim20, wherein said blocking means is movable between a retracted positionand a position intersecting said hole creating position in response tosaid second drive means.
 24. The apparatus according to claim 22,wherein said control means is programmable to set a desired operatingspeed of said needle positioning apparatus and said laser.
 25. Theapparatus according to claim 24, wherein said desired operating speed isin the range of between about 1 Hz and about 10 Hz.
 26. The apparatusaccording to claim 24, wherein said desired operating speed is 4 Hz. 27.The apparatus according to claim 20, further comprising:first hoppermeans attached to said frame for supplying needles to said guide means;and means associated with said first hopper means for preventing theneedles from binding in said hopper means.
 28. The apparatus accordingto claim 27, wherein said binding preventing means comprises a rotatabletoothed wheel positioned within said first hopper means.
 29. Theapparatus according to claim 27, further comprising second hopper meansattached to said frame for receiving the needle shanks after boring of ahole in said needle shanks.
 30. The apparatus according to claim 21,further comprising imaging means for verifying alignment of the needlewith a focal plane of said laser, said imaging means having a focalplane aligned with the focal plane of said laser.
 31. The apparatusaccording to claim 20, wherein said first drive means comprises:a motor;first drive shaft means operatively connected to said motor; first cammeans connected to said first drive shaft means for reciprocating saidpusher means and said guide means; and clutch means connected to saidfirst drive shaft means for preventing rotation of said first driveshaft means when the needle shank is in said hole creating position. 32.The apparatus according to claim 31, wherein said second drive meanscomprises:second drive shaft means operatively connected to said firstdrive shaft means for transmitting rotational movement from said firstdrive shaft means to said second drive shaft means; and second cam meanssecured to said second drive shaft means for reciprocating said jawmeans and said blocking means.
 33. The apparatus according to claim 32,further comprising cycle end switch means for disengaging said clutchmeans when the needle is positioned in said hole creating position. 34.The apparatus according to claim 20, wherein the frame includes meansfor adjusting the position of the axis of the needle shank within saidhole creating position such that the hole created by said laser extendslinearly along the longitudinal axis of the needle shank.
 35. Theapparatus according to claim 34, wherein the axis adjustment meansprovides five axes adjustment of the needle.
 36. The apparatus accordingto claim 20, wherein said jaw means comprises:a fixed jaw member securedto said frame and positioned in aligned communication with said holecreating position; and a movable jaw member slidably secured to saidframe such that said movable jaw member reciprocates into alignedcommunication with said hole creating position in opposition to saidfixed jaw member in response to said second drive means.
 37. Theapparatus according to claim 20, wherein said guide means comprises:afirst member slidably positioned on said frame to facilitate positioningof the needle in said hole creating position, said first member beingoperatively connected to said first drive means such that said firstmember reciprocates between a first position in aligned communicationwith said hole creating position and a second open position; and asecond member slidably positioned on said frame to facilitatepositioning of the needle in said hole creating position, said secondmember being operatively connected to said first drive means such thatsaid second member is movable between said needle receiving position andsaid hole creating position.
 38. An apparatus for positioning surgicalneedle shanks for laser drilling, which comprises:a frame; guide meanssecured to said frame for transferring a needle shank between a needlereceiving position and a hole creating position; blocking means slidablysecured to said frame for positioning the needle shank a predetermineddistance from a laser; pusher means slidably secured to said frame forsliding the needle shank towards said blocking means such that theneedle shank is positioned from said laser said predetermined distance;jaw means slidably secured to said frame for maintaining the needle insaid hole creating position; first hopper means secured to said framefor supplying needles to said guide means; control means for controllingthe operation of said needle positioning apparatus; and imaging meansfor verifying alignment of the needle in said hole creating positionwith a focus plane of the laser drill, said imaging means having a focalplane aligned with the focal plane of the laser drill.
 39. The apparatusaccording to claim 38, further comprising:means for verifying thepresence of the needle shank in said hole creating position; means forinhibiting the laser from activating in response to an indication of theabsence of a needle shank from said verifying means, said inhibitingmeans being electrically connected to said control means; and cycle endswitch means for disengaging said drive means when the needle is in saidhole creating position.
 40. The apparatus according to claim 38, furthercomprising means associated with said first hopper means for preventingthe needle shanks from binding within said first hopper means.
 41. Theapparatus according to claim 38, further comprising second hopper meansreleasably secured to said frame for receiving the needles after boringof a hole in said needle shank.
 42. The apparatus according to claim 38,further comprising means for driving said guide means, said blockingmeans, said pusher means and said jaw means in a predetermined sequence.43. The apparatus according to claim 28, wherein said blocking means ismovable between a retracted position and a position intersecting saidhole creating position in response to said drive means.
 44. A system forboring ahole in needle shanks, which comprises:a laser; means forcontinuously feeding needle shanks to a predetermined positionat a rateof between about 1 Hz. and about 10 Hz., such that the needle shank isaligned within a focal plane of said laser; and means for adjusting saidneedle shank, such that the hole created by said laser extends linearlyalong the longitudinal axis of the needle shank.
 45. A system for boringa hole in needle shanks, which comprises:a laser; means for continuouslyfeeding needle shanks to a predetermined position, such that the needleshank is aligned within a focal plane of said laser; and means foradjusting said needle shank, such that the hole created by said laserextends linearly along the longitudinal axis of the needle shank;wherein said feeding means includes:a frame; guide means secured to saidframe for transferring a needle shank between a needle receivingposition and a hole creating position; blocking means slidably securedto said frame for positioning the needle shank a predetermined distancefrom said hole boring device; pusher means slidably secured to saidframe for sliding the needle shank to abut said blocking means, suchthat the needle shank is positioned from said hole boring device saidpredetermined distance; jaw means slidably secured to said frame formaintaining the needle shank in said hole creating position; and meansfor driving said guide means, said blocking means, said pusher means andsaid jaw means in a predetermined sequence.
 46. A method for creating ahole in a plurality of needle shanks, comprising:sequentially feeding aplurality of needle shanks at a rate of speed substantially equal to thecycle speed of a laser into a hole creating position with thelongitudinal axis of each needle shank in substantial alignment with apredetermined axis of said laser; aligning each of said sequentially fedneedle shanks with the end face of each needle shank disposedsubstantially at for focus of said laser, such that the hole to becreated by said laser will extend substantially linearly along thelongitudinal axis of each needle shank; and activating said laser tocreate the hole in each needle shank.
 47. A method for creating a holein a plurality of needle shanks, comprising:sequentially advancing aplurality of needle shanks at a rate between about 1Hz. and about 10 Hz.into a hole creating position such that the longitudinal axis of eachneedle shank is in substantial alignment with a predetermined axis of alaser to permit creating a hole along the longitudinal axis of eachneedle shank; and activating said laser to create the hole in eachneedle shank.
 48. The method according to claim 48, wherein theplurality of needle shanks are sequentially fed at a rate of speed of 4Hz.
 49. A method for creating a hole in a plurality of needle shanksusing an apparatus for presenting needle shanks to hole creating means,said apparatus having frame means, guide means secured to said framemeans for transferring each needle shank between needle receiving andhole creating positions, blocking means slidably secured to said framemeans for positioning each needle shank a predetermined distance fromsaid hole creating means, pusher means movably secured to said framemeans for moving each needle shank to abut said blocking means, suchthat each needle shank is positioned said predetermined distance fromsaid hole creating means, and jaw means slidably secured to said framemeans for maintaining the needle shank in said hole creating position,comprising:sequentially advancing a plurality of needle shanks at a ratebetween about 1Hz and about 10 Hz into said hole creating position suchthat the longitudinal axis of each needle shank is in substantialalignment with a predetermined axis of a said hole creating means topermit creating a hole along the longitudinal axis of each needle shank;and activating said hole creating means to create the hole in eachneedle shank.
 50. The method according to claim 49, whereinsaid holecreating means is a laser.